Terex Z60H-3506 Operator's Manual
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Terex Z60H-3506 Operator's Manual

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Operator's Manual
Z
-60 DC
®
Z
-60 FE
®
Serial Number Range
from Z60H-3506
from Z60M-1200
AUS
Australia
with
Maintenance
Information
Original Instructions
Fourth Edition
Second Printing
Part No. 1315864GT

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Summary of Contents for Terex Z60H-3506

  • Page 1 Operator's Manual Serial Number Range -60 DC ® from Z60H-3506 from Z60M-1200 Australia -60 FE ® with Maintenance Information Original Instructions Fourth Edition Second Printing Part No. 1315864GT...

  • Page 2: Table Of Contents

    Maintenance ............62 Specifications ............66 Copyright © 2016 Terex Corporation Fourth Edition: Second Printing, October 2023 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with AS 1418.10 -60 DC •...

  • Page 3: Introduction

    Fourth Edition • Second Printing Operator's Manual Introduction Intr oducti on About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Fourth Edition • Second Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level swtich Platform level, jib boom up/down, primary boom extend/retract, primary boom Platform rotate switch up/down, and secondary boom retract/lower.
  • Page 5 Fourth Edition • Second Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 Operator's Manual Fourth Edition • Second Printing Introduction Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material.

  • Page 7: Symbol And Hazard Pictorials Definitions

    Fourth Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine.
  • Page 8 Operator's Manual Fourth Edition • Second Printing Symbol and Hazard Pictorials Definitions Wheel load Wind speed Maximum capacity Manual force Batteries used as counterweights Tie-down point Lifting point Platform tie-down Lifting and tie down Lanyard anchorage instructions instructions points Corrosive acid. Color coded direction Runaway hazard Collision hazard...
  • Page 9 Fourth Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Electrocution hazard Avoid contact Disconnect battery Voltage rating for Pressure rating for air power to platform line to platform Recovery procedure if tilt alarm sounds while elevated. Platform uphill: Platform downhill: Read the operator’s Read the service...

  • Page 10: General Safety

    Operator's Manual Fourth Edition • Second Printing General Safety Gener al Safety -60 DC • Z -60 FE Part No. 1315864GT ® ®...
  • Page 11 Fourth Edition • Second Printing Operator's Manual General Safety -60 DC • Z -60 FE Part No. 1315864GT ® ®...
  • Page 12 Operator's Manual Fourth Edition • Second Printing General Safety -60 DC • Z -60 FE Part No. 1315864GT ® ®...
  • Page 13 Fourth Edition • Second Printing Operator's Manual General Safety -60 DC • Z -60 FE Part No. 1315864GT ® ®...
  • Page 14 Operator's Manual Fourth Edition • Second Printing General Safety -60 DC • Z -60 FE Part No. 1315864GT ® ®...

  • Page 15: Personal Safety

    Fourth Edition • Second Printing Operator's Manual Personal Safety Pers onal Safety Personal Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform.

  • Page 16: Work Area Safety

    Operator's Manual Fourth Edition • Second Printing Work Area Safety Electrocution Hazards Work Ar ea Safety Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the ground proximity to electrical current.
  • Page 17 Fourth Edition • Second Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds boom unless the machine with the platform uphill: is on a firm, level surface. Lower the primary boom. Lower the secondary boom.
  • Page 18 Operator's Manual Fourth Edition • Second Printing Work Area Safety Use extreme care and Do not alter or disable machine components that slow speeds while driving in any way affect safety and stability. the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 19 Fourth Edition • Second Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this the maximum uphill, downhill or side slope rating machine.
  • Page 20 Operator's Manual Fourth Edition • Second Printing Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the Be aware of the boom position and tailswing when...
  • Page 21 Fourth Edition • Second Printing Operator's Manual Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Do not operate the machine with a hydraulic oil or and steer functions. air leak.
  • Page 22 Operator's Manual Fourth Edition • Second Printing Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
  • Page 23 Fourth Edition • Second Printing Operator's Manual Work Area Safety Electrocution/Burn Hazards Panel Cradle Safety Connect the battery charger to a Read, understand and obey all warnings and grounded, AC 3-wire electrical instructions provided with the panel cradles. outlet only. Do not exceed the rated platform capacity.
  • Page 24 Operator's Manual Fourth Edition • Second Printing Work Area Safety Lockout After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 25: Legend

    Fourth Edition • Second Printing Operator's Manual Legend Leg end Non-steer tire Platform controls Steer tire Platform Power to charger 10 Swing gate Ground controls 11 Lanyard anchorage points Secondary boom 12 Sliding mid-rail Primary boom 13 Foot switch Jib boom 14 Manual storage container -60 DC •...

  • Page 26: Controls

    Operator's Manual Fourth Edition • Second Printing Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 27 Fourth Edition • Second Printing Operator's Manual Controls LCD display 11 Jib boom up/down switch At machine start up the LCD screen displays Move the jib boom switch up and the jib boom pitch and roll angles of the machine, the will raise.
  • Page 28 Operator's Manual Fourth Edition • Second Printing Controls Platform Control Panel -60 DC • Z -60 FE Part No. 1315864GT ® ®...
  • Page 29 Fourth Edition • Second Printing Operator's Manual Controls -60 DC • Z -60 FE Part No. 1315864GT ® ®...
  • Page 30 Operator's Manual Fourth Edition • Second Printing Controls Platform Control Panel Function speed control switch Move the switch to the left and the function Horn button speeds for jib up/down, platform rotate and Press this button and the horn will sound. primary boom extend/retract will decrease.
  • Page 31 Fourth Edition • Second Printing Operator's Manual Controls 12 Drive speed select switch 11 Dual axis proportional control handle for drive and steer functions. Machine on incline symbol: Low range operation with reduced drive speed Proportional control handle for drive function for improved control.
  • Page 32 Operator's Manual Fourth Edition • Second Printing Controls 15 Machine mode select switch: FE Models Move the switch to the left to select DC mode Move the switch to the right to select Hybrid mode 16 Proportional control handle for secondary boom up/down function Move the control handle up and the secondary...

  • Page 33: Inspections

    Fourth Edition • Second Printing Operator's Manual Inspections Ins pections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 34 Operator's Manual Fourth Edition • Second Printing Inspections Pre-operation Inspection  Wear pads  Tires and wheels  Be sure that the operator’s manual is  FE models: Engine and related complete, legible and in the storage container components located in the platform. ...
  • Page 35 Fourth Edition • Second Printing Operator's Manual Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 36 Operator's Manual Fourth Edition • Second Printing Inspections At the Ground Controls Test Auxiliary Controls FE Models: Select a test area that is firm, level and free of hazards. 10 Turn the key switch to ground control. Turn the key switch to ground control. 11 Pull out the red Emergency Stop button to the on position.
  • Page 37 Fourth Edition • Second Printing Operator's Manual Inspections At the Platform Controls Test the Tilt Sensor FE Models: 25 Turn the key switch to platform control. 17 Select a test area that is firm, level and free of 26 Pull out the red Emergency Stop button to the hazards.
  • Page 38 Operator's Manual Fourth Edition • Second Printing Inspections Test the Foot Switch Test Machine Functions DC Models: 39 Press down the foot switch. 32 Do not press down the foot switch. Test each 40 Activate each machine function control handle machine function.
  • Page 39 Fourth Edition • Second Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 44 Press down the foot switch. 47 Press down the foot switch and lower the boom to the stowed position. 45 Slowly move the drive control handle in the direction indicated by the blue arrow on the 48 Rotate the turntable until the primary boom control panel until the machine begins to...
  • Page 40 Operator's Manual Fourth Edition • Second Printing Inspections Test Limited Drive Speed Test Drive Tilt Cutout 51 Press down the foot switch. 61 Press down the foot switch. 52 Raise the primary boom approximately 2 ft / 62 With the boom fully stowed, drive the machine 61 cm.
  • Page 41 Fourth Edition • Second Printing Operator's Manual Inspections 70 With the boom fully stowed, drive the machine 77 Return to level ground and extend the primary onto a slope where the chassis pitch angle is boom approximately 1.6 ft / 0.5 m. greater than 2.5°.
  • Page 42 Operator's Manual Fourth Edition • Second Printing Inspections Test the Oscillating Axle (if equipped) Test the Lift/Drive Select Function (if equipped) 85 Drive the right steer tire up onto a 6 in/15 cm block or curb. 92 Press down the foot switch. Result: The three remaining tires should stay 93 Move the drive control handle off center and in firm contact with the ground.
  • Page 43 Fourth Edition • Second Printing Operator's Manual Inspections 98 Operate each machine function. Test the Contact Alarm (if equipped) Result: All machine functions should not 94 Do not activate the foot switch and press on operate. the contact alarm cable to release the actuator from the switch socket.
  • Page 44 Operator's Manual Fourth Edition • Second Printing Inspections Test Aircraft Protection Package (if equipped) Note: Two people may be required to perform this test. 101 Extend the primary boom approximately 1 ft/30 cm. 102 Move the yellow bumper at the bottom of the platform 4 inches/10 cm in any direction.
  • Page 45 Fourth Edition • Second Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris Do Not Operate Unless:  sloped surfaces  unstable or slippery surfaces You learn and practice the principles of safe ...
  • Page 46 Operator's Manual Fourth Edition • Second Printing Inspections Inspection for Decals with Words Part No. Decal Description Z-60DC 218550 Danger – Tip-over Hazard, 500 lbs / 227 kg Use the pictures on the next page to verify that all 218559 Danger, Warning –...
  • Page 47 Fourth Edition • Second Printing Operator's Manual Inspections 1315548 -60 DC • Z -60 FE Part No. 1315864GT ® ®...
  • Page 48 Operator's Manual Fourth Edition • Second Printing Inspections Inspection for Decals with Words Part No. Decal Description Z-60FE 147792 Danger – Tire Specifications** 218550 Danger – Tip-over Hazard, 500 lbs / Use the pictures on the next page to verify that all 227 kg decals are legible and in place.
  • Page 49 Fourth Edition • Second Printing Operator's Manual Inspections 1315548 -60 DC • Z -60 FE Part No. 1315864GT ® ®...

  • Page 50: Operating Instructions

    Operator's Manual Fourth Edition • Second Printing Operating Instructions Operati ng Instr ucti ons Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety, and responsibilities manuals.
  • Page 51 Fourth Edition • Second Printing Operator's Manual Operating Instructions Machine Operation FE Models: Starting the Engine From the ground control panel: FE models can be operated with or without the engine running. Turn the key switch to ground control. Turn the key switch to ground or platform Be sure both ground and platform control red control.
  • Page 52 Operator's Manual Fourth Edition • Second Printing Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Note: When operating the machine from the platform, the following foot switch messages may Pull out the red Emergency Stop button to the appear on the platform control LCD screen.
  • Page 53 Fourth Edition • Second Printing Operator's Manual Operating Instructions To Steer Driving on a slope Press down the foot switch. Determine the uphill, downhill and side slope ratings for the machine and determine the slope Slowly move the drive control handle in the grade.
  • Page 54 Operator's Manual Fourth Edition • Second Printing Operating Instructions To determine the slope grade: Drive Enable Measure the slope with a digital inclinometer OR LCD symbol on indicates that use the following procedure. the boom has moved just past either non-steer wheel and the You will need: drive function has been carpenter’s level...
  • Page 55 Fourth Edition • Second Printing Operator's Manual Operating Instructions Machine Not Level LCD Symbol Tilt Sensor Activation Settings If the tilt alarm sounds when the Model Parallel to boom Perpendicular to structure boom structure platform is raised, the Machine Not Level LCD symbol will come on Z-60 DC 2.5°...
  • Page 56 Operator's Manual Fourth Edition • Second Printing Operating Instructions Function Speed Control Contact Alarm (if equipped) The contact alarm is designed to alert ground Move the switch to the personnel when an operator makes contact with left to decrease the the platform control panel, interrupting boom function speeds for jib movement, sounding an alarm and flashing...
  • Page 57 Fourth Edition • Second Printing Operator's Manual Operating Instructions Aircraft Protection Package (if equipped) Panel Cradle Assembly Apply the warning decal to the front of each If the platform bumper comes panel cradle (if needed). into contact with an object, the machine will shut down and no Install rubber bumper 1 in the panel cradle functions will operate.
  • Page 58 Operator's Manual Fourth Edition • Second Printing Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rails. Position the padding to protect the panels from contact with the platform rails. Installation of Strap Open the clamp and install it around a vertical platform rail tube.
  • Page 59 Fourth Edition • Second Printing Operator's Manual Operating Instructions FE Models: Charging Batteries with Engine Running the engine will automatically charge the batteries. The engine will automatically shut off when the battery charge cycle reaches 85%. After the charge cycle reaches 85% the platform Battery and Charger Instructions control panel LCD screen will display the following message, HYBRID CHARGE COMPLETE.
  • Page 60 Operator's Manual Fourth Edition • Second Printing Operating Instructions Dry Battery Filling and Charging Instructions After Each Use This procedure applies to flooded lead acid Select a safe parking location—firm level batteries only. surface, clear of obstruction and traffic. Remove the battery vent caps and Retract and lower the boom to the stowed permanently remove the plastic seal from the position.

  • Page 61: Transport And Lifting Instructions

    Fourth Edition • Second Printing Operator's Manual Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons Be sure the turntable is secured with the  turntable rotation lock before transporting. Be sure to unlock the turntable for operation. ...
  • Page 62 Operator's Manual Fourth Edition • Second Printing Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Chassis Transit Use chains of ample load capacity. Always use the turntable rotation lock pin each Use a minimum of 6 chains. time the machine is transported.
  • Page 63 Fourth Edition • Second Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.

  • Page 64: Maintenance

    Operator's Manual Fourth Edition • Second Printing Maintenance Maintenanc e Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components.
  • Page 65 Fourth Edition • Second Printing Operator's Manual Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 66 Operator's Manual Fourth Edition • Second Printing Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 67 Fourth Edition • Second Printing Operator's Manual Maintenance Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine. Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.

  • Page 68: Specifications

    Operator's Manual Fourth Edition • Second Printing Specifications Specific ati ons Model Z-60 DC Maximum slope rating, stowed position, 4WD Height, working maximum 65 ft 7 in 20 m Platform downhill 45% 24° Height, platform maximum 59 ft 7 in 18.16 m Platform uphill 45% 24°...
  • Page 69 Fourth Edition • Second Printing Operator's Manual Specifications Model Z-60 FE Maximum slope rating, stowed position, 4WD Height, working maximum 65 ft 7 in 20 m Platform downhill 45% 24° Height, platform maximum 59 ft 7 in 18.16 m Platform uphill 45% 24°...
  • Page 70 Operator's Manual Fourth Edition • Second Printing Specifications Z-60 DC and Z-60 FE Range of Motion Max Height Max Reach Chart 80 ft 24.4 m -10 ft -3 m 70 ft 21.3 m 0 ft 60 ft 18.3 m 10 ft 50 ft 15.2 m 20 ft...

This manual is also suitable for:

Genie z-60 feGenie z-60 dcZ60m-1200

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